Hydrogen storage bed system including an integrated thermal management system

ABSTRACT

A hydrogen storage bed system which includes a pressure container, a hydrogen storage alloy disposed within the pressure container, and an integrated thermal management system integrally disposed within the pressure container. The integrated thermal management system includes heat generation means, cooling means adapted to use an aerosol coolant, and heat distribution means.

RELATED APPLICATIONS

[0001] This application is a continuation-in-part of U.S. Pat.application Ser. No. 09/742,827 filed on Dec. 20, 2000 for Ovshinsky etal.

FIELD OF THE INVENTION

[0002] The instant invention solves the vexatious thermal managementproblems that have, to date, plagued hydrogen storage bed systems. Therevolutionary design includes an integrated thermal management systemwhich evenly and efficiently heats and cools hydrogen storage alloysthat are able, for the first time to realistically use the mostubiquitous, ultimate source of fuel for the next millennium and beyond,hydrogen. More particularly, there is described the integration of heatgenerators, such as catalytic combustors, cooling devices, such as heatexchangers adapted to use an aerosol coolant, and a heat distributionsystem, such as thermal bus bars or heat pipes in combination with heatdistribution fins.

BACKGROUND OF THE INVENTION

[0003] Hydrogen, as a fuel, has enormous energy capacity and, whenoxidized or burned, produces only water as a product of that combustion.The facts of its ease of burning, its effectively pollution-freeburning, combined with the relative ease of modification of existingpower sources, including the internal combustion engine makes hydrogenan ideal source of energy for energy-hungry economies. StanfordOvshinsky and his research teams with Energy Conversion Devices havelong recognized the potential value of hydrogen as the ultimate fuel. Inlight of that recognition, development efforts have continued in supportof means for storage (U.S. Ser. No. 09/435,497 filed Nov. 6, 1999) andtransportation of hydrogen including an infrastructure in support of ahydrogen economy (U.S. Ser. No. 09/444,810 filed Nov. 22, 1999).

[0004] While hydrogen is the ultimate fuel, its storage andtransportation presents difficulties. In the liquid state, hydrogen issubject to severe losses due to vaporization; additionally there is aninitial high energy cost in compression and refrigeration to attain itsliquid state. In the gaseous state, to approach economic storagecapacities, hydrogen must be compressed, containment of such compressedgas requires heavy-walled containers which themselves must be heavy andof sturdy build. The Ovshinsky teams have addressed these needs, asnoted above, through development of hydrogen storage alloys; metals andmetallic alloys having high storage capacity for hydrogen as well ashigh rates of hydrogen charging and discharging at comparatively lowtemperatures.

[0005] The development of such high-capacity solid storage material inwhich the hydrogen is stored within the molecular or crystallinestructure of the material has been key to solution of a related yetstill different concern within a hydrogen-energy based economy. That isthe dependable, repeatable storage and release of hydrogen in smallquantities for portable uses, especially for portable motive powerneeds. For such applications, it is necessary to be able to reliably andefficiently fully charge the storage material and discharge the samewhich is on-board to run the motive power source which may be a hydrogencombustion engine, hydrogen fuel-cell running an electric motor, orother hydrogen-consuming motive system. Coupled with these needs is aneed to assure that such a system and its container is able to withstandthe constant vibration associated with motive transportation. Aspreviously described by the Ovshinsky teams, metal hydride materialshave recently become a focus of general interest as a means ofsolid-state hydrogen storage generally and for reliable on-demand oras-needed storage and dispensing of hydrogen for motive power intransportation applications.

[0006] Energy production for motive power is a large and growingfraction of the contribution of troublesome “greenhouse gases” beingconstantly added in huge volumes to the Earth's atmosphere. Of these,carbon dioxide, being produced in greater volumes, is particularlyonerous of these simply because it is produced in extremely largevolumes as a product of combustion of carbon-based fuels, as well ascarbon monoxide, another of the greenhouse gases carrying additionalburdens of toxicity during respiration. Use of hydrogen as a fuel simplyeliminates the production of the oxides of carbon and produces onlywater as a product of its combustion. Replacement of gasoline, liquefiedpetroleum gases (LPG's), alcohols, fuel oils, or other carbon-basedfuels with hydrogen, particularly in motive fuel applications, willprovide tremendous reduction in the production and release of suchglobal-warming and toxic materials.

[0007] As noted in the previously mentioned '810 application, carefulthermal management of the hydrogen storage material is critical to thereliable cycling of hydriding and dehydriding, or charging anddischarging of metal hydrides or other storage materials. The inventorsnow provide here means for controlling the release of heat duringcharging or refueling as well as generating and controlling theapplication of heat during discharge or use of the fuel from theon-board storage container or bed of hydrogen storage material. Theseinventors have developed and now disclose means for selectively orevenly heating or cooling the storage bed as needed for both use intransit for power generation and refueling of the “gas tank” at the“filling station”. This is accomplished by design of heating and coolingmeans, or combinations thereof with in the bed of storage materialcoupled with means for conveying heat or cooling capacity to distantareas in such a storage bed. Also of consideration, and part of thebelow-described invention is thermal insulation of the inside of thestorage container from the atmosphere to assure that the thermalmanagement is conducted as intended for smooth operation of whatevermotive vehicle is being operated from such a fuel-storage bed.

[0008] Additionally, the storage containers of this invention may besized in generally infinite volumes and dimensions, they may also becombined into systems by addition of multiple usefully-sized containers.Effectively, the inventors here have developed and now provide hydrogenfuel carrying and storage capacity for motive vehicles of any use,shape, or size including, but not limited to cars, trucks, trains,aircraft and watercraft. Application of hydrogen fuel to move thesevehicles will be a large step toward serious and useful reduction of thecurrently, and sometimes catastrophically, occurring global warming.

SUMMARY OF THE INVENTION

[0009] The instant invention comprises a hydrogen storage bed systemwhich includes a pressure container, a hydrogen storage alloy disposedwithin the pressure container, and an integrated thermal managementsystem integrally disposed within the pressure container. The integratedthermal management system includes heat generation means, cooling meansadapted to use an aerosol coolant, and heat distribution means.

[0010] The heat generation means one or more of electrical heatingelements and catalytic combustors, with the latter preferred. Thecatalytic combustors are designed to combust one or more of hydrogen,gasoline, fuel oil, propane, diesel fuel, or natural gas, with propaneand hydrogen preferred. The cooling means comprises a tube-type heatexchanger designed to utilize air, hydrogen, water or organic coolants.Air, hydrogen and water are the preferred coolants. A particularlyuseful coolant is an air/water aerosol. The heat generation means andthe cooling means (which is adapted to use an aerosol coolant) can becombined into a single unit designed heat and cool.

[0011] The heat distribution means can include heat sinks thermallycoupled to both said heat generation means and said cooling means andheat distribution fins thermally coupled to said heat sinks anddispersed within the hydrogen storage alloy. The heat distribution finsand heat sinks are formed from a material selected from the groupconsisting of thermally conductive graphite, stainless steel, magnesiumand magnesium alloys. Alternatively, the heat distribution means caninclude heat pipes thermally coupled to both said heat generation meansand said cooling means instead of heat sinks. The heat distribution finsthermally coupled to the heat pipes and dispersed within the hydrogenstorage alloy. Once again, the heat distribution fins are formed from amaterial selected from the group consisting of thermally conductivegraphite, stainless steel, magnesium and magnesium alloys.

[0012] The hydrogen storage alloy is selected from the group consistingof Ti—Zr based alloys and Mg based alloys. The preferred high capacityMg-based storage alloys contain greater than about 90 weight %magnesium, and contain at least one modifier element. The at least onemodifier element creates a magnesium based alloy which is capable ofstoring at least 7 weight % hydrogen and is capable of absorbing 80% ofthe full storage capacity of hydrogen in under 1.5 minutes at 300° C.The modifier elements mainly include Ni and Mm (misch metal) and canalso include additional elements such as Al, Y and Si. Thus the alloyswill typically contain 0.5-2.5 weight % nickel and about 1.0-4.0 weight% Mm (predominantly contains Ce and La and Pr). The alloy may alsocontain one or more of 3-7 weight % Al, 0.1-1.5 weight % Y and 0.3-1.5weight % silicon. The hydrogen storage alloy is in the form of powder,pellets or a mixture thereof, with the latter preferred.

[0013] The pressure container is formed from one or more materialsselected from the group consisting of stainless steel or fiberreinforced polymers. The preferred pressure container is a multilayerstructure, such as a three layered structure which includes 1) an innerlayer formed from a lightweight material which is non-reactive withhydrogen and said storage alloy, and can withstand the operatingtemperature of the system, 2) a middle layer formed from a lightweightinsulating material; and 3) an outer layer formed from a fiberreinforced polymer composite material which contains the operatingpressure of the bed system.

[0014] The hydrogen storage bed system may also include thermocouplesdisposed throughout the interior of the hydrogen storage alloy todetermine the state of charge of the system by observing temperaturespikes in discharged areas of the alloy.

[0015] Finally, the system may include a hydrogen gas distributionsystem to enhance the speed of hydriding/dehydriding of the storagealloy. The distribution system typically includes a distributionmanifold and one or more hydrogen permeable gas distribution tubes.

BRIEF DESCRIPTION OF THE FIGURES

[0016]FIG. 1 is a schematic depiction of a transverse-cross-sectionalview of one embodiment of a hydrogen storage bed system of the instantinvention;

[0017]FIG. 2 depicts an external view of a storage bed system 1according to the instant invention having a multilayered pressurecontainer;

[0018]FIG. 3 is a plot of grams of stored hydrogen versus time inminutes for both air and water cooling of a storage bed system 1according to the instant;

[0019]FIG. 4 is plot of temperature versus time during discharge ofhydrogen from a storage bed system 1 according to the instant, thetemperatures, which were taken by thermocouples distributed throughoutthe storage bed, indicates that the heat management system is effective;

[0020]FIG. 5 is a schematic depiction of a transverse-cross-sectionalview of a second embodiment of a hydrogen storage bed system of theinstant invention, similar to, but larger than, the system of FIG. 1;

[0021]FIG. 6 is a schematic depiction of a transverse-cross-sectionalview of a third embodiment of a hydrogen storage bed system of theinstant invention including a combined heating/cooling means;

[0022]FIG. 7 is a schematic depiction of a transverse-cross-sectionalview of a fourth embodiment of a hydrogen storage bed system of theinstant invention including planar combined heating/cooling meanslayered between layers of hydrogen storage alloy;

[0023]FIG. 8a is a schematic depiction of a lengthwise-cross-sectionalview of a fifth embodiment of a hydrogen storage bed system of theinstant invention, including heat pipes instead of heat sinks in theheat distribution means;

[0024]FIG. 8b is a schematic depiction of a transverse-cross-sectionalview of the fifth embodiment of a hydrogen storage bed system of FIG.5a;

[0025]FIG. 9a is a schematic depiction of a lengthwise-cross-sectionalview of a sixth embodiment of a hydrogen storage bed system of theinstant invention, including a different configuration of heat pipes;and

[0026]FIG. 9b is a schematic depiction of a transverse-cross-sectionalview of the sixth embodiment of a hydrogen storage bed system of FIG.6a.

DETAILED DESCRIPTION OF THE INVENTION

[0027] The instant invention includes solid-state, metal-hydride,hydrogen storage bed systems with integrated heat generation and heatexchange. The instant storage system includes storage alloys that adsorband desorb hydrogen for storage and subsequent use in applications suchas, for example, to power an automobile. The instant storage bed systemsinclude one or more integral heat generation devices to provide therequired heat to release the stored hydrogen from the hydrogen storagealloy. The heat generation device is also integrated with the coolingsystem which removes the heat of hydride formation when the storagealloy is being charged with hydrogen. The system also includes heatdistribution means to transfer heat between locations within the systemwhich are remote from the heating/cooling devices. The heat distributionmeans are provided to evenly supply/remove heat from the system, thusmaintaining a uniform temperature throughout the entire system. Detailsof the instant invention will be discussed herein below with respect tospecific embodiments.

[0028]FIG. 1 is a schematic depiction of a transverse-cross-sectionalview of one embodiment of a hydrogen storage bed system 1 of the instantinvention. The system 1, includes a pressure container 2 within which iscontained a hydrogen storage alloy 3. The integrated thermal managementsystem includes heat generation means 4 and cooling means 5. As usedherein, the terms “heating means” and “heat generation means” are usedinterchangeably and are meant to designate in-situ heat generationmeans. The heating and cooling means are in intimate thermal contactwith a heat distribution system which includes a heat sink 6 withdistributed heat distribution fins 7. During charging of hydrogen intothe hydrogen storage alloy 3, heat generated by hydride formation in thestorage alloy 3 is transferred to the distribution fins 7, which is thentransferred to the heat sink 6, and ultimately to the cooling means 5.During discharge of hydrogen from storage alloy 3, heat is generated inthe heat means 4, transferred to the heat sink 6, further transferred tothe distribution fins 7 and finally to the storage alloy 3, where it isused to release the hydrogen.

[0029] The pressure container 2 can be formed from any material ormaterials that contains the equilibrium pressure of hydrogen at theoperating temperatures of the storage bed system 1. The materials mustalso be non-reactive with the stored hydrogen and the hydrogen storagealloy 3 and must withstand the typical operating temperature of thesystem. The materials must also not allow for hydrogen diffusiontherethrough and not be subject to hydrogen embrittlement over thelifetime of the cotainer. The temperatures and pressures will of coursedepend on the particular storage alloy 3 that is used. Typically for amagnesium based alloy, the pressures can range up to 20 bar, andtemperatures will range up to 450° C. Typical construction materials forthe pressure container 2 can include metals such as stainless steels.The pressure container 2 can also be made thermally insulative byconstructing the container out of insulative materials or by insulatingthe exterior or interior of a thermally conductive material such as ametal. Whether or not the pressure container 2 is insulated will dependon whether or not external heating and cooling through the pressurecontainer are employed. If there is external heating and cooling, theninsulating the pressure container 2 would defeat the purpose thereof.The pressure container 2 can also be made of fiber reinforced polymericmaterials such as carbon fiber reinforced epoxy materials, etc., aloneor in conjunction with other materials (i.e. a multilayer pressurecontainer). The advantage of such fiber reinforced polymer andmultilayer construction materials is savings in weight. FIG. 2 depictsan external view of a storage bed system 1 according to the instantinvention having a multilayered pressure container 2, hydrogeninput/output port 14 and heating/cooling ports 13. The inset of FIG. 2shows the multilayer structure of the pressure container 2. The innerlayer 10 is formed from a lightweight material which is non-reactivewith hydrogen and the storage alloy 3, and can withstand the operatingtemperature of the system. The middle layer 11 is a lightweightinsulating material designed specifically to minimize heat loss from thebed system to the environment. Finally, the outer layer is a fiberreinforced polymer composite that contains the operating pressure of thebed system.

[0030] Any alloy which safely and efficiently stores and releaseshydrogen may be used as the hydrogen storage alloy 3 in the storagesystem 1 of the instant invention. Specifically useful are alloys suchas Ti—Zr based AB₂, room temperature hydrogen storage alloys and highcapacity Mg-based storage alloys. Most useful are the high capacity,high kinetics storage alloys fully described in copending U.S. patentapplication Ser. No. 09/435,497, entitled “High Storage Capacity AlloysEnabling a Hydrogen-based Ecosystem”, filed on Nov. 6, 1999 forOvshinsky et al. (“the '497 application”).

[0031] In general the high capacity Mg-based storage alloys containgreater than about 90 weight % magnesium, and contain at least onemodifier element. The at least one modifier element creates a magnesiumbased alloy which is capable of storing at least 7 weight % hydrogen andis capable of absorbing 80% of the full storage capacity of hydrogen inunder 1.5 minutes at 300° C. The modifier elements mainly include Ni andMm (misch metal) and can also include additional elements such as Al, Yand Si. Thus the alloys will typically contain 0.5-2.5 weight % nickeland about 1.0-4.0 weight % Mm (predominantly contains Ce and La and Pr).The alloy may also contain one or more of 3-7 weight % Al, 0.1-1.5weight % Y and 0.3-1.5 weight % silicon.

[0032] The storage alloy 3 can be used in the storage system 1 in theform of a powder or can be pelletized as described in U.S. applicationSer. No. 09/634,678, entitled “Safe, Economical Transport of Hydrogen inPelletized Form”, filed Aug. 8, 2000 for Ovshinsky et al. While the useof powdered materials may in some cases facilitate loading of the powderinto the system. However, powder can be difficult to handle andhazardous to use, thus in some instances loading the system 1 withpelletized storage alloy will be advantageous. Additionally, it is oftendifficult to get a high enough packing density of storage alloy 3 in thestorage bed system 1 when using only powder. Thus, it may be useful toload the storage alloy 3 into the storage bed system 1 in the form of amixture of powder and pellets.

[0033] During discharge of the hydrogen stored in these aforementionedhydrogen storage alloys 3, heat is required to release the hydrogen fromthe alloys. Generally, there are a number of ways in which this heat canbe provided. For example, when hydrogen is to be supplied to an internalcombustion engine, the heat can come from the exhaust of the engineitself. However, the instant invention is designed to be used whenlittle or no external heat is available, such as when the hydrogen is tobe supplied to a fuel cell. Thus, another source of heat is needed.

[0034] The heat generation means 4 provides the heat needed to releasethe stored hydrogen. The heat generation means 4 can be any means togenerate, in-situ, the heat needed to discharge hydrogen from thestorage alloy 3. Specifically, the heat generation means may includeelectrical heating elements, catalytic combustors. Catalytic combustorsand the catalytic combustion process is well known in the art and arethe preferred means for heat generation. Catalytic combustorsessentially work by chemically combining a fuel (such as hydrogen or ahydrocarbon) and an oxidizer (such as oxygen or air) in the presence ofa catalyst upon which the fuel and the oxidizer are reacted to formcombustion products, and heat. This heat is then transferred, directlyor indirectly, to the surroundings (the hydrogen storage alloy in thecase of the instant invention).

[0035] The catalytic combustor provides an internal heat source forheating the hydrogen storage alloy 3 of the instant invention. A typicalcatalytic combustor comprises a nonporous chamber which does not permitthe flow of either oxygen, hydrogen or combustion products between theinterior of the combustor and the metal-hydride material or other heattransfer means. Preferably, the chamber is formed from a nonporous,thermally conductive material. Housed within the chamber is a catalyst.Generally, the catalyst is one which can lower the activation energy ofcombustion reaction. Fuel passes into and though the combustor alongwith compressed air or oxygen. The catalyst catalyzes the reactionbetween the fuel and the oxygen (or oxygen in air). The heat generatedfrom catalytic combustion is used to heat the hydrogen storage alloy inthe storage system up to a temperature at which the hydride materialdesorbs hydrogen. At this point, the heat produced by the combustor doestwo things: (1) it maintains the temperature of the metal-hydridestorage material (i.e., compensates for heat transfer out of thematerial), and (2) provides the heat of desorption of hydrogen from thehydrogen storage alloy.

[0036] While hydrogen itself can be burned or catalytically combusted toprovide the necessary heat to release the stored hydrogen, this reducesthe useable hydrogen available to power other devices, such as a fuelcell, thus increasing the weight and volume of the storage bed requiredto supply a fixed mass of hydrogen. For instance, in a typical fuel cellvehicle, some of the stored hydrogen may be needed to provide the heatnecessary to release all of the stored hydrogen and heat up thesurrounding components (i.e. casings, heat transfer components, etc.).Obviously it is necessary to minimize this loss of available hydrogen.Thus a secondary fuel may be used. The secondary fuel may be any fuelwhich is readily available, inexpensive and easily stored. Examples ofsuch a fuel are gasoline, fuel oil, propane, diesel fuel, natural gas,etc. The preferred fuel is propane, and the preferred method of storingthe propane is in liquid form. Specifically, it is noted that merely twogallons of propane would be needed to release all the stored hydrogenrequired to travel 300 miles with a typical hydrogen powered fuel cellvehicle. This makes the vehicle a very low emission vehicle.

[0037] The cooling means 5, removes heat produced during charging of thehydrogen storage alloy 3. That is, during charging of hydrogen to thestorage alloy 3, heat is released (i.e. heat of hydriding). To maintainthe proper operating temperature during charging, this heat must beremoved. The cooling means 5 are typically heat exchanger devices suchas a coolant flowing through a tube or other enclosed space. The coolantmay be any conventional coolant such as air or water. The coolant mayalso be hydrogen, which, as described in U.S. application Ser. No.09/558,827, entitled “A Hydrogen Cooled Hydrogen Storage Unit HavingMaximized Cooling Efficiency”, filed Apr. 26, 2000 for Ovshinsky et al.,makes an excellent cooling medium. The coolant may also be any of theorganic materials used in the art as a coolant as well as phase changecoolants.

[0038] One particularly useful coolant is an aerosol and even moreparticularly an air-water aerosol. This coolant is highly effective fora number of reasons. First, the aerosol will be much more effective atcooling than air alone because of the energy consuming evaporationeffect of the liquid (e.g. water). For example, when the microdropletsof water are heated to their boiling point, they will evaporate, thusremoving from the storage system the additional heat required forvaporization. Thus, since the aerosol is more effective at cooling thanair alone, the volume of air required to cool the system will bereduced, thereby reducing air pumping costs. Secondly, the aerosol ismore useful than just water alone in that the output temperature of theair/steam mixture is higher than if water alone were used for thecooling. This higher temperature makes the waste heat removed from thesystem by the aerosol more easily recovered and reused. In addition toreduced air requirements, the volume of water used is also reduced,thereby reducing costs. Preferred air-water aerosols will contain up toabout 30 weight percent water.

[0039] Of course, the water used in the aerosol should preferably bedistilled water, with no contaminant ions such as sodium, calcium,magnesium, iron, etc. This helps to prevent scaling of the coolingsystem. The distilled water can, if desired, be recovered when the wasteheat is recovered from the air/steam exit stream. The recovered watercan then be reused in the cooling aerosol.

[0040] The materials for forming the exchanger will depend upon thespecific coolant used. The materials must be non-reactive with thecoolant, hydrogen, and the storage alloy 3 and must be able to withstandthe typical operating temperatures of the system 1. Specific materialswill be thermally conductive and may include metals such as stainlesssteel or other thermally conductive materials.

[0041] When an air-water aerosol is used as the coolant, the coolingmeans 5 will be adapted to use this coolant. This adaptation mayconstitute selection of materials that are physically and chemicallyinert to the corrosive effects of water and high temperature steam. Theadaptation will further include providing an aerosol nozzle or otherdevice to create the aerosol, preferably somewhere near the inlet to thecooling means 5. Nozzles, atomizers and other devices to create such anair-water aerosol are well known in the art and, as such, are notfurther discussed herein.

[0042] In an alternative embodiment, the heat generation means 4 and thecooling means 5 may be combined into one means (see for example FIG. 6).By combining these two means into one, the overall weight and volume ofthe storage bed system 1 is significantly reduced. This combination canmost advantageously occur when air or hydrogen is used as the coolantmedium. This is because during heating of the system (required fordischarging), both a fuel and air are inserted into the catalyticcombustors and react to heat the storage bed system 1. Alternatively,during cooling (required when charging), air or hydrogen is individuallyinserted into the catalytic combustor and the inserted gas acts as acoolant, removing the heat of hydride formation. If this alternative isused, it may be necessary to reduce the coverage of catalyst on theinterior of the heating means to enhance heat transfer to the coolantmedium.

[0043] The heat sink 6 is thermally connected to the heat generationmeans 4 and the cooling means 5. The heat sink 6 evenly distributes heatfrom the heating means 4 to the heat distribution fins 7 duringdischarge of hydrogen, and accepts heat from the heat distribution fins7 transferring it to the cooling means 5 during charging of hydrogen.The combination of heat sink 6 and heat distribution fins 7 ensuresproper heat transfer throughout the entire storage bet system 1, andalso insures that the entire storage bed system 1 is at as uniform atemperature as possible. The heat sink 6 and the heat distribution fins7 are preferably, but not necessarily, formed from the same material.The material should be as light weight as possible but needs to bethermally conductive. The material must also not be reactive with thestored hydrogen or the hydrogen storage alloy and able to withstand thetypical operating temperatures of the system 1.

[0044] The heat sink 6 and the heat distribution fins 7 can preferablybe formed from a metal such as stainless steel, with the preferred metalbeing magnesium or a structural magnesium alloy. Magnesium and alloysthereof are thermally conductive, light weight, thermally andstructurally sound and generally non-reactive with the stored hydrogenand the storage alloy 3. The heat sink 6 and the heat distribution finsmay also me made from thermally conductive graphite. The heat sink 6 islarge enough to act as a heat reservoir or thermal mass for heat as itis transferred into or out of the system 1. The large reservoir insuresthat the heat within the system 1 is fairly uniformly distributedthroughout the bulk of the system (i.e. the hydrogen storage materialsand the heat distribution fins 7). The heat sink 6 is shaped such thatall of the heat distribution fins 7 can be evenly disposed throughoutthe entire mass of the hydrogen storage alloy 3.

EXAMPLE

[0045] A bed system 1 was produced according to the embodiment ofFIG. 1. The system 1 consists of a cylindrical pressure container 2,formed from stainless steel, within which is contained a magnesium basedhydrogen storage alloy 3. The Mg alloy, designated FC-76, had acomposition: 95.6 wt. % Mg, 1.6 wt. % Ni, 0.8 wt. % Si and 2.0 wt % Mm.The integrated thermal management system includes electrical heatgeneration means 4 and tube-type heat exchange cooling means 5 throughwhich both air and water coolants were passed. The heating and coolingmeans are in intimate thermal contact with the heat sink 6 which isformed from pure magnesium and is shaped generally as a rectangular slabwhich is positioned within the cylindrical pressure container 2 suchthat the length of the slab traverses the length of the cylinder and thewidth of the slab traverses a diameter of the cylinder. Heatdistribution fins 7 are thermally attached to the heat sink 6. The heatdistribution fins 7 project out from the heat sink 6 and are fairlyevenly distributed throughout the mass of hydrogen storage alloy 3. Theheat distribution fins 7 are formed from formed from pure magnesium andare shaped as rectangular plates. The rectangular plates or foil heatdistribution fins 7 are disposed within the cylindrical pressurecontainer 2 such that the length thereof traverses the length of thecylinder. One edge of the rectangular plate heat distribution fins 7 isin thermal contact with the heat sink 6 and the opposing edge isadjacent to the pressure container 2.

[0046] One and a third kilograms of the FC-76 magnesium based hydrogenstorage alloy powder 3 was packed into the bed system 1 at a packingdensity of about 0.6 g/cc (this could be enhance by packing both powderand pellets). The system was charged and had a storage capacity of about85 grams of hydrogen. As shown in FIG. 3, which is a plot of grams ofstored hydrogen versus time in minutes, both air and water cooling wereeffective to allow for proper charging. Curve A shows the storedhydrogen versus time for air cooling and curve B is for water cooling.As can be seen, both coolants are effective, but the water coolingclearly allows for faster charging, essentially completing a chargingcycle in less than 10 minutes.

[0047]FIG. 4 is plot of temperature versus time during discharge ofhydrogen from the storage bed. The temperatures were taken bythermocouples distributed throughout the storage bed. Curve A plots thetemperature (also measured by thermocouple) of the electric heater usedto heat the alloy and thus discharge the stored hydrogen. As can clearlybe seen, the temperature of the storage bed system is fairly uniformthroughout, thus demonstrating that the instant thermal managementsystem is effective. The temperature increase near the end of the curvesindicated a rise in the temperature of the system as the charge ofhydrogen is depleted.

[0048]FIG. 5 is a schematic depiction of a transverse-cross-sectionalview of a second embodiment of a hydrogen storage bed system 1 of theinstant invention. Similar to the system of FIG. 1, the system 1 of thisembodiment includes a pressure container 2 within which is contained ahydrogen storage alloy 3. The integrated thermal management of thissystem includes seven heating means 4 and seven cooling means 5 (whichcan be integrated into dual purpose heating and cooling means). Theheating and cooling means are in intimate thermal contact with a heatdistribution system which includes a three heat sinks 6 with evenlydistributed heat distribution fins 7. In this system, the three heatsinks 6 are fairly evenly spaced throughout the pressure container 2 andsome of the heat distribution fins 7 are disposed such that opposingedges are in thermal contact with two heat sinks 6.

[0049]FIG. 6 is a schematic depiction of a transverse-cross-sectionalview of a third embodiment of a hydrogen storage bed system 1 of theinstant invention. The system 1, includes a cylindrical pressurecontainer 2 within which is contained a hydrogen storage alloy 3. Theintegrated thermal management system includes a combined heating/coolingmeans 8, which is a hollow coiled spiral disposed within the cylindricalpressure container 2, wherein the central axis of the hollow coiledspiral is coincidental with the central axis of the cylindrical pressurecontainer 2. The interior of the hollow coiled spiral is coated with acatalytic material to form a catalytic combustor. Thus, the interior ofthe hollow coiled spiral acts as a heater when fuel and an oxidizer arepassed therethrough, and as a cooler when a coolant gas (such as air orhydrogen) is passed therethough.

[0050] It should be noted that since the hollow coiled spiral is inintimate thermal contact with and highly distributed throughout thehydrogen storage alloy 3, additional heat distributions components, suchas heat sinks and thermal distribution fins, are not necessary. However,if it is found that heat is not evenly distributed within the system 1,these heat distributions components may be added as necessary.

[0051]FIG. 7 is a schematic depiction of a cross-sectional view of afourth embodiment of a hydrogen storage bed system 1 of the instantinvention. The system 1, includes a pressure container 2 within which iscontained a hydrogen storage alloy 3. The pressure container has arectangular or square cross-section and may have an elongated axis or bemore cubelike. The hydrogen storage alloy 3 is disposed in the pressurecontainer in layers between which is disposed the integrated thermalmanagement system includes combined heating/cooling means 8. Thecombined heating/cooling means 8 are hollow plates disposed between thelayers of hydrogen storage alloy 3. The interior of the hollow plate iscoated with a catalytic material to form a catalytic combustor. Thus,the interior of the hollow plate acts as a heater when fuel and anoxidizer are passed therethrough, and as a cooler when a coolant gas(such as air or hydrogen) is passed therethough. It should be noted thatsince the hollow plates are in intimate thermal contact with and arehighly distributed throughout the hydrogen storage alloy 3, additionalheat distributions components, such as heat sinks and thermaldistribution fins, are not necessary. However, if it is found that heatis not evenly distributed within the system 1, these heat distributionscomponents may be added as necessary.

[0052]FIG. 8a is a schematic depiction of a lengthwise-cross-sectionalview of a fifth embodiment of a hydrogen storage bed system 1 of theinstant invention. The system 1, includes a cylindrical pressurecontainer 2 within which is contained a hydrogen storage alloy 3. Theintegrated thermal management system includes at least one combinedheating/cooling means 8, which is a hollow disk disposed within thecylindrical pressure container 2, wherein the central axis of the hollowdisk is coincidental with the central axis of the cylindrical pressurecontainer 2. The interior of the hollow disk is coated with a catalyticmaterial to form a catalytic combustor. Thus, the interior of the hollowdisk acts as a heater when fuel and an oxidizer are passed therethrough,and as a cooler when a coolant gas (such as air or hydrogen) is passedtherethough. The heating/cooling means 8 are in intimate thermal contactwith a heat distribution system which includes heat pipes 9 anddistributed heat distribution fins 7. One end of the heat pipes 9 is inthermal contact with one of the circular surfaces of the combinedheating/cooling means hollow disk 8. The heat pipes extend along thelength of the cylindrical pressure container 2 from the combinedheating/cooling means 8, in the both directions, to the ends of thecylindrical pressure container 2. The heat distribution fins 7 arecylindrical disks evenly disposed within the cylindrical pressurecontainer 2 between the combined heating/cooling means 8 and the ends ofthe cylindrical pressure container 2. The central axis of the heatdistribution fins 7 is coincidental with the central axis of thecylindrical pressure container 2. The heat distribution fins 7 are inthermal contact with the heat pipes 9, and extend axially to theinterior wall of the cylindrical pressure container 2.

[0053]FIG. 8b is a schematic depiction of a transverse-cross-sectionalview of the fifth embodiment of a hydrogen storage bed system 1 of FIG.8a. The figure shows the positioning within the system 1, of thecylindrical pressure container 2 and the hydrogen storage alloy 3.Specifically shown is the manner in which the heat pipes 9 aredistributed within the system 1 and how the heat pipes 9 extend alongthe length of the cylindrical pressure container 2.

[0054] A heat pipe is a device utilizing an evaporation and condensationcycle for transferring heat from a hot or heat input region to a cold orheat output region thereof with minimum temperature drop. One type ofheat pipe comprises a closed container within which is included a layerof wicking material saturated with a vaporizable liquid and extendingfrom the heat input region to the heat output region thereof. Theaddition of heat at the heat input region of the container evaporatesthe liquid being supplied thereto. The vapor moves to the heat outputregion of the container where it is condensed. The condensed liquid isreturned to the heat input region by capillary action in the wickingmaterial. It should be noted that while the heat pipes described in thespecific embodiments of the instant invention are pipe shaped, modernheat pipe technology allows for nearly any hollow shape to be used informing a heat pipe, and thus other shapes are possible and may beuseful.

[0055]FIG. 9a is a schematic depiction of a lengthwise-cross-sectionalview of a sixth embodiment of a hydrogen storage bed system 1 of theinstant invention. The system 1, includes a cylindrical pressurecontainer 2 within which is contained a hydrogen storage alloy 3. Theintegrated thermal management system includes at least one combinedheating/cooling means 8, which is a hollow rectangular plate disposedwithin the cylindrical pressure container 2 such that the length of thehollow traverses the length of the cylinder and the width of the hollowrectangular plate traverses a diameter of the cylinder. Theheating/cooling means 8 are in intimate thermal contact with a heatdistribution system which includes heat pipes 9 and distributed heatdistribution fins 7. One end of the heat pipes 9 is in thermal contactwith one of the large rectangular surfaces of the combinedheating/cooling means hollow plate 8. The heat pipes extend from thethermal contact with the heating/cooling means 8 outward in a generallyperpendicular direction from the large rectangular surfaces of thecombined heating/cooling means hollow plate 8 to the wall of thecylindrical pressure container 2. The heat distribution fins 7 arerectangular plates or foil which are disposed within the cylindricalpressure container 2 such that the length thereof traverses the lengthof the cylinder. The rectangular plates or foil are disposed within thecylindrical pressure container 2 generally parallel to theheating/cooling means hollow plate 8, and the length of the rectangularplates or foil traverses the length of the cylinder and the width of theslab traverses from one point on the interior wall of the cylinder toanother point on the interior wall of the cylinder. The heatdistribution fins 7 are in thermal contact with the heat pipes 9.

[0056]FIG. 9b is a schematic depiction of a transverse-cross-sectionalview of the sixth embodiment of a hydrogen storage bed system 1 of FIG.9a. The figure shows the positioning within the system 1, of thecylindrical pressure container 2 and the hydrogen storage alloy 3.Specifically shown is the manner in which the heat pipes 9 aredistributed within the system 1 and how the heat pipes 9 extend alongthe a diameter width of the cylindrical pressure container 2 and thepositioning of the heat distribution fins 7.

[0057] It should be noted that a plurality of storage bed systems of theinstant invention can be bundled together in a larger container. Thiscontainer may be insulated and may provide for external heating andcooling of the storage bed systems. The container may also be a pressurecontainment vessel. Additionally, thermocouples may be placed within thestorage bed system to monitor the temperature throughout different partsof the system, and thus by measuring temperature spiking at differentlocations, the volume of fuel can be determined. Further, eachindividual storage bed system may be wrapped externally with a heatingmeans. This may include electrical heating tapes, wires, blankets, etc.

[0058] Finally, the hydrogen storage bed system 1 of the instantinvention can include a hydrogen gas distribution system to enhance thespeed of hydriding/dehydriding of the storage alloy. The distributionsystem typically includes a distribution manifold and one or morehydrogen permeable gas distribution tubes distributed throughout thehydrogen storage alloy. This hydrogen distribution system can include abypass of blowoff hydrogen collection bed. This bed can be used torecapture unadsorbed hydrogen. The bed would consist of a lowtemperature hydrogen storage alloy. The bed would be attached to thesystem in such a way as to recapture any hydrogen that may not beadsorbed into the hydrogen storage material. This may be hydrogen thatwas used to cool the bed system or hydrogen that was intended to bestored in the bed but, for whatever reason, it was not.

[0059] While the invention has been described in connection withpreferred embodiments and procedures, it is to be understood that it isnot intended to limit the invention to the described embodiments andprocedures. On the contrary it is intended to cover all alternatives,modifications and equivalence which may be included within the spiritand scope of the invention as defined by the claims appendedhereinafter.

We claim:
 1. A hydrogen storage bed system including: a pressurecontainer; a hydrogen storage alloy disposed within said pressurecontainer; and an integrated thermal management system integrallydisposed within said pressure container including: heat generationmeans; cooling means, said cooling means adapted to use an aerosolcoolant; and heat distribution means.
 2. The hydrogen storage bed systemof claim 1, wherein said cooling means are adapted to use an air/wateraerosol coolant.
 3. The hydrogen storage bed system of claim 2, whereinsaid cooling means include a means to create said air/water aerosol. 4.The hydrogen storage bed system of claim 3, wherein said means to createsaid air/water aerosol include a nozzle or atomizer.
 5. The hydrogenstorage bed system of claim 1, wherein said heat generation means isselected from the group consisting of electrical heating elements andcatalytic combustors.
 6. The hydrogen storage bed system of claim 5,wherein said heat generation means is one or more catalytic combustors.7. The hydrogen storage bed system of claim 6, wherein said catalyticcombustors are designed to combust at least one fuel selected from thegroup consisting of hydrogen, gasoline, fuel oil, propane, diesel fuel,and natural gas.
 8. The hydrogen storage bed system of claim 1, whereinsaid heat distribution means includes heat sinks thermally coupled toboth said heat generation means and said cooling means.
 9. The hydrogenstorage bed system of claim 8, wherein said heat distribution meansfurther includes heat distribution fins thermally coupled to said heatsinks and dispersed within said hydrogen storage alloy.
 10. The hydrogenstorage bed system of claim 9, wherein said heat distribution fins andsaid heat sinks are formed from a material selected from the groupconsisting of thermally conductive graphite, stainless steel, magnesiumand magnesium alloys.
 11. The hydrogen storage bed system of claim 1,wherein said heat distribution means includes heat pipes thermallycoupled to both said heat generation means and said cooling means. 12.The hydrogen storage bed system of claim 11, wherein said heatdistribution means further includes heat distribution fins thermallycoupled to said heat pipes and dispersed within said hydrogen storagealloy.
 13. The hydrogen storage bed system of claim 12, wherein saidheat distribution fins are formed from a material selected from thegroup consisting of thermally conductive graphite, stainless steel,magnesium and magnesium alloys.
 14. The hydrogen storage bed system ofclaim 1, wherein said hydrogen storage alloy is selected from the groupconsisting of Ti—Zr based alloys and Mg based alloys.
 15. The hydrogenstorage bed system of claim 1, wherein said system further comprises ahydrogen gas distribution system to enhance the speed ofhydriding/dehydriding of said storage alloy.
 16. The hydrogen storagebed system of claim 15, wherein said hydrogen gas distribution systemincludes a distribution manifold and one or more hydrogen permeable gasdistribution tubes distributed throughout said hydrogen storage alloy.17. The hydrogen storage bed system of claim 16, wherein said hydrogengas distribution system further includes a recapture tank including ametal hydride for recapturing unadsorbed hydrogen.
 18. The hydrogenstorage bed system of claim 1, wherein said integrated thermalmanagement system further comprises: heat conducting projectionsextending and distributed within said pressure container in heattransfer contact with said hydrogen storage alloy; and a heating/coolingsink positioned within said pressure container and connected in heattransfer relationship to said heat conducting projections and to saidheat generation means and said cooling means; whereby heat istransferred to said hydrogen storage alloy from said heat generationmeans and from said hydrogen storage alloy to said cooling means throughsaid heat conducting projections and said heating/cooling sink.
 19. Thehydrogen storage bed system of claim 14, wherein said Mg based alloy hasa composition of 95.6 wt. % Mg, 1.6 wt. % Ni, 0.8 wt. % Si and 2.0 wt %Mm.